LED Lighting Assembly and Method of Lighting for a Merchandise Display

ABSTRACT

Aspects of the disclosure relate to a lighting assembly and method for illuminating a vertical planar area, such as a merchandise display. The lighting assembly can comprise two opposing support arms and a lighting bar extending between the two opposing support arms, a circuit board having a plurality of LEDs mounted to the inside of the lighting bar; and a plurality of reflective surfaces located adjacent to the plurality of LEDs, wherein the plurality of reflective surfaces are positioned such that the LEDs project a first light beam in a first direction and a second light beam in a second direction different than the first direction.

CROSS REFERENCE TO RELATED APPLICATIONS

This Application is a continuation of U.S. patent application Ser. No.14/965,514, filed Dec. 10, 2015, which is a continuation of U.S.application Ser. No. 13/790,983, filed Mar. 8, 2013, and issued on Dec.29, 2015, as U.S. Pat. No. 9,222,645, which is a continuation-in-part ofU.S. application Ser. No. 13/162,076, filed Jun. 16, 2011, which is acontinuation-in-part of U.S. application Ser. No. 12/955,198, filed Nov.29, 2010, now U.S. Pat. No. 8,864,334 issued Oct. 21, 2014. U.S.application Ser. No. 13/790,983, filed Mar. 8, 2013, and issued on Dec.29, 2015, as U.S. Pat. No. 9,222,645 also claims priority to U.S.Provisional Application No. 61/608,374, filed Mar. 8, 2012. U.S.application Ser. No. 12/955,198, filed Nov. 29, 2010, now U.S. Pat. No.8,864,334 issued Oct. 21, 2014 also claims priority to U.S. ProvisionalApplication No. 61/355,757, filed Jun. 17, 2010. All of the above listedapplications are herein incorporated by reference in their entirety.

FIELD OF INVENTION

This invention relates generally to LED lighting assemblies for amerchandise display and methods of lighting. In particular, in oneaspect of the invention, an LED light assembly is provided with aplurality of reflective surfaces located adjacent to the LEDs, whereinthe reflective surfaces are positioned such that the LED projects afirst light beam in a first direction and the reflective surface directsa second light beam in a second direction different than the firstdirection.

BACKGROUND

In many retail stores it is desired to illuminate the front of productpackages on merchandise display shelves to improve the productpresentation, shopping environment, and to highlight products toultimately improve the overall sales of the products.

Typically, this is accomplished with a fluorescent lighting fixture,which is located above a shelving unit and emits light down upon thefront of the shelves. However, in most existing installations of thistype, much of the light is not used because it is not captured anddirected to the front of the shelves. Lack of focusing, specificreflectors, or beam modification results in product on higher shelvesbeing too brightly illuminated and product on lower shelves receivingvery little light at all.

Additionally, there are also significant costs with replacing lamps onfluorescent fixtures when they deteriorate or burn out including thecosts of new lamps and labor to replace the lamps. In addition, when thelamps are replaced on the scale of a large retail chain, replacement canbecome environmentally harmful since all fluorescent lamps containmercury.

In one exemplary aspect of the present invention, more of the availablelight is directed to the front of products merchandised on a shelf and ahigher illuminance per watt of power is output than with existingfluorescent fixtures. In another exemplary aspect of the presentinvention, a lower cost lighting solution is disclosed that uses lessenergy, directs and improves the illumination on the product packages,particularly on the lower shelves, and requires lower maintenance costs.

SUMMARY

The following presents a general summary of aspects of the invention inorder to provide a basic understanding of the invention and variousfeatures of it. This summary is not intended to limit the scope of theinvention in any way, but it simply provides a general overview andcontext for the more detailed description that follows.

In one exemplary embodiment, a lighting assembly for a merchandisedisplay is disclosed. The lighting assembly can comprise: (a) twoopposing support arms and a lighting bar extending between the twoopposing support arms, (b) a circuit board assembly having a pluralityof LEDs mounted to the inside of the lighting bar, wherein the pluralityof LEDs project a light in a beam pattern on a merchandise display; and(c) a plurality of reflective surfaces located adjacent to the LEDs,wherein the reflective surfaces are positioned such that the LEDprojects a first light beam in a first direction and the reflectivesurface directs a second light beam in a second direction different thanthe first direction. The lighting assembly may also include lensesplaced over a corresponding one or more of the plurality of LEDs, andwherein the lenses capture the light from a respective LED, modify thebeam pattern, and re-project the light.

In another exemplary embodiment, a lighting method for a merchandisedisplay is disclosed. The method can comprise: (a) arranging a pluralityof LEDs on a circuit board located within a lighting bar, wherein theplurality of LEDs project a light in a beam pattern on a merchandisedisplay; (b) securing a plurality of reflective surfaces adjacent to theLEDs, wherein the reflective surfaces are positioned such that the LEDprojects a first light beam in a first direction and the reflectivesurface directs a second light beam in a second direction different thanthe first direction. The lighting method may also include (c) securing aplurality of lenses to the circuit board; and (d) placing the pluralityof lenses over one or more of the LEDS on the lighting bar so as tocapture the light from a respective LED, modify a beam pattern emittedfrom the respective LED, and re-project the light emitted from therespective LED.

Other objects and features of the invention will become apparent byreference to the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention and certainadvantages thereof may be acquired by referring to the followingdetailed description in consideration with the accompanying drawings, inwhich:

FIG. 1 shows a perspective view of exemplary lighting assemblies in useon a merchandise display;

FIG. 2 shows another perspective view of exemplary lighting assemblies;

FIGS. 3A and 3B show top views of an exemplary circuit board assemblycontained in the lighting assemblies;

FIG. 4 shows a perspective view of the exemplary circuit board assembly;

FIG. 5 shows a bottom perspective view of another exemplary lightingassembly;

FIG. 6 shows a top perspective view of the exemplary lighting assemblyshown in FIG. 5;

FIG. 7 shows a cross-section view of the exemplary lighting assemblyfrom FIG. 5;

FIG. 8 shows a bottom perspective view of another exemplary lightingassembly;

FIGS. 9A through 9C show various beam angles for exemplary LEDs used inaccordance with this disclosure;

FIGS. 10A and 10B show cross-section views of embodiments of theexemplary lighting assembly from FIG. 8;

FIG. 11A and 11B show cross-section views of other embodiments of theexemplary lighting assembly from FIG. 8; and

FIG. 12 shows a cross-section view of another embodiment of theexemplary lighting assembly from FIG. 8.

The reader is advised that the attached drawings are not necessarilydrawn to scale.

DETAILED DESCRIPTION

In the following description of various example structures in accordancewith the invention, reference is made to the accompanying drawings,which form a part hereof, and in which are shown by way of illustrationof various structures in accordance with the invention. Additionally, itis to be understood that other specific arrangements of parts andstructures may be utilized, and structural and functional modificationsmay be made without departing from the scope of the present invention.Also, while the terms “top” and “bottom” and the like may be used inthis specification to describe various example features and elements ofthe invention, these terms are used herein as a matter of convenience,e.g., based on the example orientations shown in the Figures and/or theorientations in typical use. Nothing in this specification should beconstrued as requiring a specific three dimensional or spatialorientation of structures in order to fall within the scope of thisinvention.

FIGS. 1 and 2 depict exemplary LED lighting assemblies 10 for amerchandise display. As shown in FIGS. 1 and 2, the LED lightingassemblies 10 each include a housing 12, a circuit board assembly 24,and a circuit board 16 having an LED driver circuit 22 (shown in FIG.3B). The housing 12 can include a series of clamps 28 for securing thehousings above the area being illuminated. A plurality of LED emitters20 are mounted to the circuit board 16 and are powered with the LEDdriver circuit 22. As shown in FIG. 4, the LEDs are spaced apart fromeach other along the circuit board assembly 24. The circuit boardassembly 24 is also connected to a power cord 18.

The lenses 14 can be secured over individual LED emitters 20 to providedifferent refractive properties for reflecting the light emitted by theLEDs in various angles and directions such as over product shelves. Asshown in FIGS. 3A and 3B, the lenses 14 can be provided with differentrefractive configurations. However, alternatively, the lenses can all beprovided with the same refractive configurations. In another alternativeembodiment, the lenses may be placed over every other LED to modify thelight pattern. Other arrangements are also contemplated to provideoptimal lighting properties and configurations depending on theenvironment and desired results.

In one exemplary embodiment, as shown in FIGS. 3A and 3B, the lenses areprovided with a spotlight beam refractive surface 15A and an oval beamrefractive surface 15B. The light emitted from the spotlight pattern 15Alenses on the circuit board assembly 14 is directed at the lowest pointsuch as a product on the bottom shelf, whereas the light emitted fromthe oval pattern 15B lenses is directed at the upper and middle areassuch as at products on the top and middle shelves. When in use in thelighting assembly, the different refractive surfaces or lens types(spotlight pattern 15A and oval pattern 15B) project the light invarious directions such that the individual patterns in aggregate fromall LED emitters, result in light more evenly distributed in a verticalplane such as over products and shelves on display.

In one exemplary embodiment, the lens types can alternate on the circuitboard assembly 24 between the spotlight pattern 15A configuration andthe oval pattern 15B configuration. This embodiment may aid in providingan evenly distributed vertical lighting area such as over productshelves. In particular, the lighting pattern is narrower near thehousing such as near the top shelves and grows wider as it travels downto the lower areas such as near the bottom shelves. Additionally, thelight from the oval pattern 15B lenses overlaps to provide for moreevenly lit areas.

The lenses 14 may be secured to the circuit board assembly 24 via a snapfit or by any other known suitable connection. The lenses may be fixedindividually, for example, one lens per one LED or one or more lensesmay be connected together to create a uniform, one-piece lens assemblythat is easier, faster, and more cost effective to install on thecircuit board assembly.

The LED lighting housing can be adjustable in several ways to adjust theorientation of the housing and to fine tune the position of theprojected light. First, the housing can be adjusted on horizontal arms(not shown) that are generally perpendicular to the long edge of theshelves and positioned above the top shelf in a set of shelves. Thisadjustment allows the LED lighting assembly to be moved closer to orfarther from the plane being illuminated. The second adjustment allowsthe assembly to rotate about its horizontal axis 26 to direct light at adifferent angle in the plane. The two adjustments change the angle atwhich the light intercepts the product faces. Moving the lightingfixture away from the product on the horizontal arms can improve thelighting on the lower positioned product by reducing shadows on theproduct caused by the lower shelves.

Each of the LED lighting assemblies 10 modify the light output from thepoint source LED emitters 20 to illuminate an artificial planar surfacearea which can be represented by a front surface of product on a shelfin a retail store. Each LED lighting assembly can be approximately thelength of a shelf in a retail store, typically 3 ft or 4 ft long, oreven as short as 6 inches or as long as 20 feet. The LED lightingassemblies 10 can be positioned in a horizontal orientation above aproduct on the top shelf and slightly in front of an artificial plane.The LED lighting assembly 10 may also be positioned in any otherlocation with respect to the product, not necessarily only in alignmentwith the shelf. The light is modified by the plurality of lenses 14fitted onto the circuit board 16 and over the LEDs 20 to capture thelight from an LED, modify the beam pattern, and re-project the lightevenly over a vertical plane in front of the product shelves.

In another exemplary embodiment, as illustrated in FIGS. 5 through 7,another lighting assembly 110 is depicted. The lighting assembly 110 (orillumination device) may include two opposing support arms 111 and alighting bar 112 extending between the two support arms 111. The twosupport arms 111 may be mountable into the support posts of a gondolatype merchandise display shelf. Typically, the support arms 111 and thelighting bar 112 are positioned above the top shelf of the merchandisedisplay system. The support arms 111 and the lighting bar 112, however,can be located at any desired position on the merchandise displaysystem.

The lighting bar 112 may define a C-shaped configuration incross-section. The lighting bar 112 may define other shapes and othersized configuration in cross-section without departing from thisdisclosure. The lighting bar 112 may act as a housing to a plurality oflight emitting diodes (LED) 120 and may be configured to mount theseLEDs 120 on the inside of the C-shaped cross section, as illustrated inFIGS. 5 and 7. The lighting bar 112 may be made of metal or any othersuitable material. The LEDs 120 may be spaced along the lighting bar 112on the inside of the lighting bar 112 as shown in FIGS. 5 and 7. TheLEDs 120 may be electrically coupled together by a circuit board 116positioned on the lighting bar 112. The circuit board 116 may alsoincorporate the appropriate resistors to control the power supplied toeach LED 120.

The LEDs 120 may provide any desired color, which may be controlled bythe semiconductor material of the LED light 120. As illustrated in FIGS.5 and 7, a reflector or lens 114 may be positioned around every otherLED 120 on the lighting bar 112. The reflectors or lens 114 may also beplaced intermittently around LEDs 120 on the lighting bar 112. Thereflector or lens 114 may also be positioned in irregular patters aroundLEDs 120 on the lighting bar 112. The reflector or lens 114 serves thepurpose of directing the emitted light in a desired direction and angle.The reflector or lens 114 may be positioned and oriented at any of thenumerous possible angles to direct light in the desired direction. Withthe use of the alternating arrangement of LEDs 120 with reflectors 114and without reflectors 114, it has been determined that the lightemitted from the lighting bar 112 covers the entire merchandise displaysystem, from the top shelf to the bottom shelf. As a result, all shelvesof the merchandise display system are properly illuminated which makesthe products on those shelves more visible and attractive to consumers.Additionally, the lens systems 14 as described in the first embodimentand illustrated in FIGS. 1 through 4 may be utilized with this lightingassembly.

It should be understood that other lighting configurations are possiblewith the lighting bar 112 to adequately direct light to the entiremerchandise display system. For example, it is possible to positionreflectors over every third or fourth LED 120, and so on. Also, it ispossible for the lighting bar 112 to define other numerous shapes andconfigurations, depending on the type of shelf and merchandise displaysystem on which the lighting bar 112 is used.

In another exemplary embodiment, as illustrated in FIGS. 8 through 12,another lighting assembly 210 is depicted. The lighting assembly 210 (orillumination device) may include two opposing support arms 211 and alighting bar 212 extending between the two support arms 211. The twosupport arms 211 may be mountable into the support posts of a gondolatype merchandise display shelf or any other similar display shelf.Typically, the support arms 211 and the lighting bar 212 are positionedabove the top shelf of the merchandise display system. The support arms211 and the lighting bar 212, however, can be located at any desiredposition on the merchandise display system.

Generally, the lighting bar 212 may define a C-shaped configuration incross-section. The lighting bar 212 may act as a housing to a pluralityof light emitting diodes (LED) 220 and may be configured to mount theseLEDs 220 on the inside of the C-shaped cross section, as illustrated inFIGS. 5 and 7. The lighting bar 212 may be made of metal or any othersuitable material. The LEDs 220 may be spaced along the lighting bar 212on the inside of the lighting bar 212 as shown in FIGS. 5 and 7. TheLEDs 220 may be electrically coupled together by a circuit board 216positioned on the lighting bar 212.

Generally, LEDs 220 output a directional beam 222. The LED 220 may alsoinclude a given beam angle 224 that is output from the LED 220. Asillustrated in FIGS. 9A-9C, LEDs 220 may have beam angles 224 ofapproximately 80 degrees, 120 degrees, or 180 degrees. LEDs with otherbeam angles 224 may be utilized or incorporated with the lightingsystem. FIG. 9A illustrates a beam angle 224 of approximately 80degrees. FIG. 9B illustrates a beam angle 224 of approximately 120degrees. FIG. 9C illustrates a beam angle 224 of approximately 180degrees.

A reflective surface 230 may be positioned near or adjacent the outputof one or more of the LEDs 220. The reflective surface 230 may allowbetter control of a portion of the beam. The reflective surface 230 mayalso allow the deflection/reflection of a portion of the beam 222.Additionally, as will be explained in detail below, the reflectivesurface 230 may also allow the splitting or dividing of the beam 222 tothereby create multiple beams 222 projecting from the LED. Asillustrated in FIGS. 10A and 10B, the reflective surface is positionedadjacent to the LED 220 and the projected beam 222 of the LED 220. Asillustrated in FIGS. 10A and 10B, the reflective surface may direct aportion of the projected beam 222 from the LED 220 in a differentdirection, thereby creating two different beams of light 222A and 222B.

In one embodiment, the reflective surface 230 may be positioned parallelto the path of the beam 222, but only covering and/or reflecting aportion of the beam 222. For example, as shown in FIG. 11A, thereflective surface 230 is positioned parallel to the path of the beam222, but only covering and/or reflecting approximately half of the beam222. The reflective surface 230 thereby allows approximately 50% of thebeam 222 to project in the direction that the LED 220 is directionallypointing (downward in this illustration), while reflecting the other 50%of the beam 222 in a direction based on the position and angle of thereflective surface 230 (horizontal in this illustration). This use ofthe reflective surface 230 with one LED 220 thereby can create twodifferent LED beams 222 using just one LED 220. FIG. 10A illustrates afirst beam 222A projecting in a downward or vertical direction, whereinthe first beam 222A is not reflected from the reflective surface 230.FIG. 10A also illustrates a second beam 222B projecting in a linear orhorizontal direction, wherein the second beam 222B is reflected by thereflective surface 230. Furthermore, as illustrated in FIG. 12, the LED220 with the reflective surface 230 may create a first beam 222A thatprojects as a down light and a second beam 222B that projects as a backlight against product shelving.

Without departing from this disclosure, the amount that the reflectivesurface reflects can be varied. In one exemplary embodiment, asillustrated in FIG. 11B, the reflective surface may allow approximately30% of the beam to project in the direction that the LED isdirectionally pointing (downward in this illustration), while reflectingthe other 70% of the beam in a direction based on the position and angleof the reflective surface (horizontal in this illustration). In anotherexemplary embodiment, the reflective surface may allow approximately 70%of the beam to project in the direction that the LED is directionallypointing, while reflecting the other 30% of the beam in a directionbased on the position and angle of the reflective surface. Thereflective surface may allow a minimal percent (just more than 0%) ofthe beam to 99% of the beam to project in the direction that the LED isdirectionally pointing, while reflecting the remaining portion of thebeam.

Generally, the reflective surface 230 may be a mirror. The reflectivesurface 230 may be other surfaces without departing from this invention,such as white/shiny, textured, or an optical film with surface coatings.Other reflective surfaces 230 not contemplated at this time may also beutilized without departing from this disclosure. The reflective surface230 may be a flat reflective surface, or a flat mirror. In anotherembodiment without departing from this disclosure, the reflectivesurface 230 may be a curved reflective surface, or a curved mirror.Other surface geometry may be utilized for the reflective surface 230without departing from this disclosure. FIG. 10A illustrates a curvedreflective surface 232. FIG. 10B illustrates a flat reflective surface234. Additionally, the reflective surface 230 may be an intermittentmirror or a continuous mirror without departing from this disclosure.

For a series of LEDs 220 on a lighting bar 212, the reflective surfaces230 may be utilized at different and specified intervals throughout theseries of LEDs 220. In one embodiment, one individual reflective surface230 may be utilized for each of the LEDs 220 on the lighting bar 212. Inanother embodiment, one continuous reflective surface 230 may beutilized for all of the LEDs 220 on the lighting bar 212. In anotherembodiment and as illustrated in FIG. 8, one individual reflectivesurface 230 may be utilized on intermittent LEDs 220 on the lighting bar212 at specified intervals throughout the series of LEDs. For example,if there are ten LEDs 220 on the lighting bar 212, there may be fivereflective surfaces 230 utilized with five of the ten individual LEDs220 on the lighting bar 212. Other combinations may be utilized withoutdeparting from this disclosure, such as ten LEDs 220 on the lighting bar212 with three of the ten individual LEDs 220 covered with a reflectivesurface 230 or ten LEDs 220 on the lighting bar 212 with seven of theten individual LEDs 220 covered with a reflective surface 230.

In conjunction with reflective surfaces 230, the LEDs 220 may alsoinclude a reflector or lens 214 positioned around one or more of theplurality of LEDs 220 on the lighting bar 212. The reflector or lens 214may serve the purpose of focusing and/or directing the emitted light ina desired direction and angle, and then projected onto the reflectivesurfaces 230. The reflector or lens 214 may be positioned and orientedat any of the numerous possible angles to direct light in the desireddirection.

It should be understood that other lighting configurations andcombinations are possible with the lighting bar 212 to adequately directlight to the entire merchandise display system. For example, it ispossible to vary and/or combine different configurations of reflectorsand reflective surfaces over various LEDs 220 on the lighting bar 212.Also, it is possible for the lighting bar 212 to define other numerousshapes and configurations, depending on the type of shelf andmerchandise display system on which the lighting bar 212 is used.

The modified light projected onto the products on the retail shelf isrelatively consistent in brightness over the planar surface and addssufficient relative brightness beyond the general store luminairelighting to call attention to or highlight the product merchandised onthe shelf. Also, utilizing the reflective surfaces and the lensingtechnique directs the available LED light such that the lighting patternproduced on the planar surface and the product faces is far morehomogenous than that of a fluorescent system. Top, center, and lowerproduct on the shelves is relatively evenly illuminated providing thedesired effect for the consumer shopper. The modified light projectedonto the products may increase shopper awareness of the products, betterpresent the products, and increase the sales of products.

By capturing and directing a higher percentage of total light outputfrom the LEDs using appropriate lensing and/or reflective surfaces, theilluminance per watt can be higher than is generally possible with afluorescent light, adding to a further reduction in necessary powerinput to achieve the desired lighting effect and energy savings.Additionally, by reflecting a portion of the total light output from theLED using appropriate reflective surfaces, the light beams can be moreefficiently utilized, thereby adding to an even further reduction in thenecessary power input to achieve the desired lighting effect and energysavings.

The LED circuit board and housing is designed to be thermally efficientand to remove as much heat from the LED as possible. Projected life ofthe LEDs is on the order of 4-6 times than that of typical existingfluorescent lamps. This reduces service call frequency by four to fivetimes and commensurate cost.

Cost savings from reduced energy use and fewer service calls, along withimproved sales from better product presentation may offset the cost ofreplacing existing fluorescent fixtures with an LED lighting fixture.

The reader should understand that these specific examples are set forthmerely to illustrate examples of the invention, and they should not beconstrued as limiting the invention. Many variations in the lightingassemblies may be made from the specific structures described abovewithout departing from this invention.

While the invention has been described in detail in terms of specificexamples including presently preferred modes of carrying out theinvention, those skilled in the art will appreciate that there arenumerous variations and permutations of the above described systems andmethods. Thus, the spirit and scope of the invention should be construedbroadly as set forth in the appended claims.

We claim:
 1. A lighting assembly for a merchandise display comprising:two opposing support arms and a lighting bar extending between the twoopposing support arms, wherein the lighting bar is defined by a C-shapedconfiguration in cross section; a circuit board assembly having aplurality of LEDs mounted to the inside of the lighting bar, wherein theplurality of LEDs project a light onto a merchandise display; and aplurality of reflective surfaces located adjacent to the plurality ofLEDs, wherein the plurality of reflective surfaces are positioned suchthat the LEDs project a first light beam in a first direction and theplurality of reflective surfaces direct a second light beam in a seconddirection different than the first direction.